Preparation Of Wear-resistant Ceramic/Polymer Coatings And Investigation Of The Properties

By the introduction of sub-micron ceramic particles of Al2O3, ZrO2 and SiC with average diameters of 0.58μm, 0.36μm and 0.5μm, respectively, the obtained ceramic/polymer coatings based on epoxy of bisphenol A presented high wear-resistance which would result in increased lifetime and lower costs for spare parts and maintenance.The dispersion of ceramic particles in polymer and interfacial adhesion between filled ceramic particles and polymer matrix were evaluated by SEM (scanning electron microscopy). The influence of ceramic particles on hardness of ceramic/polymer coatings were assessed by hardness-testing device. Friction behavior of coatings was studied by abrasion test on dry and wet condition. Corrosion resistance and bond strength about coatings were also analyzed.By optimizing the polymer composition and proper stirring method, the results showed that ceramic particles were homogeneously dispersed in polymer matrix. The hardness of composite coatings was enhanced by the increasing content of ceramic particles. When the content of SiC particles reached to 40%, significant improvement in the Rockwell hardness was above 82.5.On wet condition, introduction of sub-micron ceramic particles could improve the tribology of composite coatings. The wear-resistances of composite coatings with the same kind of ceramic particles but different content were compared. When the quality percents of Al2O3, ZrO2 and SiC were 20%, 30% and 20%, the composite coatings had the best wear-resistance and the wear rate were 0.025%, 0.027% and 0.024%, respectively. On dry condition, wear rate of composite coatings with SiC were also lower than those with Al2O3, ZrO2. Ceramic particles could improve polymer's wear-resistance. High wear-resistance of ceramic/polymer coatings are associated with the increasing of bearing capability.Epoxy coatings'main wear mechanics were micro-cutting on wet condition, when ceramic/polymer coatings'were choice wearing on soft matrix and hard material particles excavated. The erosion test showed that ceramic/polymer coatings had higher corrosion protection than epoxy coatings. Coatings should have high binding power besides wear-resistance. Tensile test showed that bond strength between coatings and matrix was strong, and the bond strength of composites filled with SiC was especially high, about 17.77MPa.